Experimental Study of Micro Electrochemical Milling with Side-Insulated Electrode

2012 ◽  
Vol 159 ◽  
pp. 127-131 ◽  
Author(s):  
Man Hong Hu ◽  
Yong Li ◽  
Zhang Yue ◽  
Wang Jian ◽  
Xiao Gu Zhu
Keyword(s):  
Experimental Study ◽  
Material Removal Rate ◽  
Sodium Nitrate ◽  
Spin Coating ◽  
Material Removal ◽  
Removal Rate ◽  
Tool Electrode ◽  
Silica Material ◽  
Micro Ecm ◽  
Electrochemical Milling

In order to study the machine effects of using side-insulated electrode during the Micro electrochemical milling, a 704-silica material is firstly introduced to fabricate the side-insulation film on the micro ECM tool electrode by spin-coating technique. The 704-silica insulation film can effectively isolate the side of tool electrode with the electrolyte and eliminate the stray corrosion. With the side-insulated electrode, triangle, square and circle columns with vertical sidewalls were successfully machined in passivat sodium nitrate electrolyte. Moreover, the material removal rate is about 2.1×104 μm3/s by using a tool electrode of Ф=100 μm in diameter.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

The Experimental Study on Mechanical Polishing on Materials with Hydrolysis Reaction

2017 ◽  
Vol 739 ◽  
pp. 182-186
Author(s):  
Hung Jung Tsai ◽  
Pay Yau Huang ◽  
Chung Ming Tan ◽  
Tang Feng Chang
Keyword(s):  
Experimental Study ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Experimental Studies ◽  
Operating Conditions ◽  
Hydrolysis Reaction ◽  
Polishing Process ◽  
Surface Polishing ◽  
Material Removal Rate Model

The hydrolytic properties of LiAlO2 (LAO) are important factors for its applications on LED fabrication. During soft pad polishing process, the H2O in the slurry is deleterious for LAO surface polishing results. The current study develops a material removal rate model for materials with hydrolysis reaction to predict the result of polishing process.The current research conducts the experimental studies to investigate the material removal rate and its mechanism during the soft pad polishing process. In the experimental study, the hydrolytic properties of LAO have been tested to understand the hydrolysis speed with different operation parameters to assist the development of the theoretical model. Also the material removal rates of LAO with hydrolytic property have been measured under different soft pad polishing operating conditions. The experimental results provide the hydrolytic properties of LiAlO2 to understanding of the mechanism on polishing process.

Chip-Ejection Mechanism and Experimental Study of Water Dispersant Dielectric Fluid on Small-Hole EDM

2010 ◽  
Vol 97-101 ◽  
pp. 4111-4115 ◽  
Author(s):  
Ming Rang Cao ◽  
Sheng Qiang Yang ◽  
Wen Hui Li ◽  
Shi Chun Yang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Tap Water ◽  
Dielectric Liquid ◽  
Small Hole ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Quality ◽  
Hole Machining

The small hole EDM is one main method of micro holes machining and applied very widely. But it’s machining efficiency is low and machining stability is bad, which is more obvious because of chip-ejection difficulty when the ratio of length to diameter is rather large. Secondary discharge caused by chip-ejection difficulty not only makes the material removal rate reduce, but also causes geometric tolerance and affects product performance. Based on dispersion mechanism study of the water dispersant, the influence of the water dispersant is analyzed to chip-ejection, material removal rate and machining quality of the high-speed small-hole EDM. By contrasting the machining effect on using tap water with disperser dielectric liquid during electric spark small hole machining, adding the certain proportion disperser in water-based dielectric liquid may increase the material removal rate, decrease the tool wear rate, improve the effective impulse numbers, obviously reduce the second discharge number, and the taper of tool electrode and hole becomes small, so the hole machining quality enhances.

High-Speed EDM Milling Using Rotating Short Arcs Under Composite Field

2021 ◽  
Author(s):  
Jin Zhang ◽  
Fuzhu Han
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Arc Discharge ◽  
Removal Rate ◽  
Tool Electrode ◽  
Electrode Wear ◽  
Comparative Experiment ◽  
Composite Field

Abstract This paper proposed a new method of high-speed electrical discharge machining (EDM) using rotating short arcs under composite field. By the Lorentz force, the electric force and the high-speed rotation of the tool electrode, rotating short arcs are generated between the tool electrode and the workpiece, which can greatly improve the material removal rate of difficult-to-cut materials such as titanium alloys and superalloys. Firstly, the machining equipment used to generate rotating short arcs was constructed. Secondly, single arc discharge experiment was carried out to investigate the motion characteristics of rotating short arcs. The result shows that the arcs can rotate between the tool electrode and workpiece under composite field. Then, the experiment of processing GH4169 was conducted to explore the machining characteristics of rotating short arcs milling, which indicated that rotating short arcs can achieve a much higher material removal rate (MRR). Additionally, it’s found that the magnetic field also has influence on debris, which is beneficial to debris removal. Finally, a comparative experiment was carried out. The MRR of rotating short arcs milling was three times than that of traditional EDM, and the tool electrode wear rate (TEWR) is only one-fifth of that of traditional EDM. The comparative experiment further verified that rotating short arcs milling can achieve higher MRR and lower TEWR.

Segmentierte Werkzeugelektroden/Segmented tool electrodes – Focused relocation of discharges in sinking EDM

2021 ◽  
Vol 111 (07-08) ◽  
pp. 501-506
Author(s):  
Eckart Uhlmann ◽  
Mitchel Polte ◽  
Jan Streckenbach ◽  
Tina Becker ◽  
Kai Thißen ◽  
...  
Keyword(s):  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrical Circuit ◽  
Tool Electrode ◽  
Electrical Discharges ◽  
Segmented Tool

Dieser Beitrag stellt Untersuchungen zu einer gezielten Umverteilung von Funkenentladungen in funkenerosiven Senkprozessen mittels Segmentierung der Werkzeugelektrode vor. Dafür wurden drei Schaltungsansätze realisiert und bewertet. Durch die gezielte Umverteilung der Funkenentladungen auf die jeweiligen Segmente konnte in ersten Versuchsreihen eine Steigerung der Abtragrate um mehr als 25 % bei gleichzeitiger Reduzierung des relativen Verschleißes um circa 48 % erreicht werden.   This paper presents an investigation into the targeted redistribution of electrical discharges in sinking EDM by segmenting the tool electrode. For this purpose, three electrical circuit approaches were implemented and evaluated. In a first series of trials with a targeted redistribution of the electrical discharges to the respective segments, an increase of the material removal rate by more than 25 % and a reduction of the relative tool wear by approximately 48 % could be achieved.

Analysis of Residual Stress Induced by Hand Grinding Process

2011 ◽  
Vol 681 ◽  
pp. 327-331 ◽  
Author(s):  
Sawsen Youssef ◽  
O. Calonne ◽  
Eric Feulvarch ◽  
P. Gilles ◽  
Hédi Hamdi
Keyword(s):  
Residual Stress ◽  
Experimental Study ◽  
Crack Initiation ◽  
Residual Stresses ◽  
Material Removal Rate ◽  
Surface Integrity ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Process ◽  
Cup Wheel

Grinding cup wheel is often used in the case of hand grinding which allows an important material removal rate but with secondary concern of surface integrity. Integrity is strongly affected by the process and consequently influences the surface behaviour in terms of resistivity to stress corrosion and crack initiation. This operation is difficult to master in terms of results on the surface and subsurface due to its manual nature. The paper presents results of an experimental study to investigate the residual stresses induced by this hand grinding process.

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